TB45 Gasoline Engine With GP40N NF-FP5 service repair manual

Service Manual For use with GP40N/NF-GP55N/NF Chassis Service Manual. 99739-31100 TB45 Gasoline Engine 111219-up

GROUP INDEX Items EG ENGINE GENERAL PRECAUTIONS FOR SAFETY AND QUALITY, HOW TO USE THIS MANUAL, TROUBLE DIAGNOSIS, ECM GENERAL SERVICE INFORMATION, PRECAUTIONS, PREPARATION, SERVICE DATA ET ENGINE TUNE-UP VALVE CLEARANCE, ENGINE DRIVE BELT, ENGINE OIL, COMPRESSION PRESSURE, SPARK PLUG EM ENGINE MECHANICAL INTAKE MANIFOLD, EXHAUST MANIFOLD, OIL PAN AND OIL STRAINER, ROCKER COVER, ROCKER ARM AND ROCKER SHAFT ASSEMBLY, CYLINDER HEAD, TIMING CHAIN, CYLINDER BLOCK LU ENGINE LUBRICATION OIL PUMP CO ENGINE COOLING SYSTEM ENGINE COOLANT, WATER PUMP, THERMOSTAT EC ENGINE CONTROL PRECAUTIONS, ENGINE CONTROL SYSTEM, TROUBLE DIAGNOSIS, BASIC INSPECTION, BATTERY AND GROUND SYSTEM, CRANKSHAFT POSITION SENSOR 1º (POS), CRANKSHAFT POSITION SENSOR 120º (REF), MASS AIR FLOW SENSOR SYSTEM, ENGINE COOLANT TEMPERATURE SENSOR SYSTEM, HEATED OXYGEN SENSOR SYSTEM, THROTTLE POSITION SENSOR SYSTEM, ACCELERATOR PEDAL POSITION SENSOR SYSTEM, NEUTRAL SWITCH SYSTEM, INTAKE AIR TEMPERATURE SENSOR SYSTEM, STOP LAMP SWITCH SYSTEM, ELECTRICAL LOAD SWITCH SYSTEM, IGNITION SYSTEM, FUEL INJECTOR SYSTEM (GASOLINE) , FUEL PUMP SYSTEM, THROTTLE CONTROL MOTOR SYSTEM, HEATED OXYGEN SENSOR HEATER SYSTEM, LPG INJECTOR SYSTEM, LPG ASSISTANCE INJECTOR SYSTEM, LPG FUEL PRESSURE SENSOR SYSTEM, LPG INTERCEPTION VALVE SYSTEM, FUEL CONTROL CHANGING SWITCH SYSTEM, PCV GAS RESTORATION DEVICE, FUEL CUT FUNCTION, ECM COMPONENTS, SERVICE DATA AND SPECIFICATIONS (SDS) FL ENGINE FUEL SYS- TEM FUEL SYSTEM, FUEL INJECTOR (GASOLINE AND COMBINED USE), LPG PARTS EL ENGINE ELECTRICAL SYSTEM STARTING SYSTEM, CHARGING SYSTEM, HIGH-TENSION CABLE GROUP INDEX EM LU CO EC FL EL EG ET

SECTION EG ENGINE GENERAL CONTENTS PRECAUTIONS FOR SAFETY AND QUALITY ............................................................. EG-2 Description ..................................................... EG-2 Safe Operation ............................................... EG-2 Correct Operation ........................................... EG-3 Precautions for Radio Equipment Installation ...................................................... EG-3 HOW TO USE THIS MANUAL ............................ EG-4 Description ..................................................... EG-4 Definition of Terms ......................................... EG-4 Definition of Units ........................................... EG-4 Description ..................................................... EG-5 Component Parts Location ............................. EG-5 TROUBLE DIAGNOSIS ...................................... EG-7 ECM Trouble Diagnosis ................................. EG-7 ECM Abbreviations List ................................ EG-10 ECM GENERAL SERVICE INFORMATION ..... EG-11 Connector Terminal Inspection .................... EG-11 Inspection for Electrical System ................... EG-12 Control Unit and Electronic Component ....... EG-13 PRECAUTIONS ................................................ EG-14 Precautions in Draining Engine Coolant ....... EG-14 Precautions for Disconnecting Fuel Piping ... EG-14 Precautions for Removing and Disassembling .............................................. EG-14 Precautions for Inspection, Correction, and Replacement ................................................ EG-14 Precautions for Assembly and Installation ... EG-14 Caution for Use of Power Tools ................... EG-15 Precautions for Liquid Gasket Application .... EG-15 Parts Requiring Angle Tightening ................. EG-16 PREPARATION ................................................ EG-17 Service Parts ................................................ EG-17 SERVICE DATA ................................................ EG-18 Periodical Inspection .................................... EG-18 Standard, Repair Limit .................................. EG-20 Tightening Torque ........................................ EG-21

EG-2 PRECAUTIONS FOR SAFETY AND QUALITY PRECAUTIONS FOR SAFETY AND QUALITY Description • The following precautions must be carefully observed for safe and appropriate service work. • Only the qualified and designated personnel must perform inspections, repairs and adjustments. • Always keep the workplace clean, and store the tools neatly in the specified places. Safe Operation • Do not run an engine inside the workshop without proper ventilation (ex. no ventilation ducts). • Keep the workshop well ventilated and free of any flammable materials. Special care should be taken when flammable or poisonous materials such as gasoline are handled. • Discard waste oil after oil changes or parts treatment in accordance with local laws and regulations. • Be careful of burns and injury when working on high- temperature parts, rotating parts, or sliding portions. • Ensure that adequate ventilation is provided for discharging any hazardous emissions when working in a pit or enclosed area. • Do not work underneath a vehicle supported only by a jack. Always use safety stands at the prescribed points to support the vehicle. • Support it at the prescribed points and lock it in position with safety devices before lifting the vehicle. • Be careful that the vehicle body does not become off balance and fall when removing a heavy component such as the engine. • Do not smoke during service work. • Do not wear any rings and necklaces when working. These objects may cause electric short. • Before starting repair work that requires no battery power, always turn OFF the ignition switch, and disconnect the negative battery cable. • Do not disconnect battery cable at negative terminal while engine is running. • Do not touch any metal portions immediately after the engine is stopped. Otherwise the heated metals may cause burns. Do not attempt to remove any cooling system parts such as the radiator cap while the engine is hot. • To perform repair work safely and efficiently, always use appropriate tools wherever required. • Do not continue filling the fuel if automatic valve of refilling nozzle is closed when fuel tank is filled. The fuel can overflow and splash, and it can cause a fire. EGM0043 EGM0044 EGM0045 EGM0046

EG-3 PRECAUTIONS FOR SAFETY AND QUALITY Correct Operation • Make sure that you understand the symptoms before starting trouble diagnosis. • Check correct installation status prior to removal or disassembly. Make sure that they do not interfere with the function of the parts they are applied to if matching marks are required. • Once they are removed, always replace parts indicated as “do not reuse” with new ones. This includes: oil seals, gaskets, packings, O-rings, lock washers, cotter pins, and self-locking nuts. • Replace inner and outer races of tapered or needle roller bearings as a set. • Arrange disassembled parts in order and prevent them from being mixed-up. • Clean or flush disassembled parts prior to inspection or assembly. • Use Genuine NISSAN parts for replacement. • Use authorized grease and sealer. • Release the pressure before disconnecting pressurized piping or hoses. • Be sure to check for leakage after repairing fuel, oil, coolant, exhaust, or vacuum systems. Precautions for Radio Equipment Installation Check the following when installing a commercial/ham radio or mobile phone. If mounting position is not chosen carefully, the unit may interfere with the electronic control system. • Separate the antenna as far from the ECM as possible. • Route an antenna feeder line at least 20 cm (7.87 in) apart from the control unit harness. • Adjust an antenna and feeder line to eliminate radio wave interference.

EG-4 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description This manual explains how to perform “removal, installation, disassembly, assembly, inspection and adjustment” and “diagnosis”. Definition of Terms WARNING : Instructions and precautions that may lead to fatal hazards and/or serious injuries if not observed properly. CAUTION : Instructions and precautions that require special attention and may lead to problems and/or accidents as well as damages to the vehicle and/or components. NOTE : Supplementary information to facilitate the service work. Standard : Indicates tolerances for inspection and adjustment. Repair limit : Indicates maximum or minimum values allowed for inspection and adjustment. Definition of Units The units and numerical values in this Standard are SI units, and those given in ( ) in this Standard are based on the conventional unit system and are appended for informative reference. Example: : 59 - 78 N•m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) SI (Metric system, yard-pound system) * The conventional unit can be used for SI. MAIN UNIT CHANGES Measure SI Conventional unit Conversion factor to SI Acceleration m/s 2 G 9.80665 Torque, moment N•m kg-m 9.80665 Force N kg 9.80665 Pressure kPa kg/cm 2 98.07 kPa mmHg 0.133322 Power efficiency kW PS 0.735499 W kcal/h 1.16279 Volume cm 3 cc 1 Spring constant N/mm kg/mm 9.80665 Fuel consumption g/kW•h * g/PS•h 1.3596

EG-5 HOW TO USE THIS MANUAL Description CAUTION : At the beginning of each section, the precautions exclusive to the section are described. Preparation: At the beginning of each section and during the trouble diagnosis items, the tools, gauges, and other tools to be prepared before operation are described. Some commercial service tools, assumed to be available in any workshop, are omitted. Description : To perform correct operations, operational procedures, notes, tools, and other service information are described. CAUTION : Descriptions of visual inspections and cleaning of removed parts are generally omitted. Please remember that actual operations require these processes. Component Parts Location The “Component Parts Location” diagram (refer to the figure) includes information for removal, installation, disassembly, and assembly (tightening torque, grease points, non-reusable parts) as well as other information important for repair work. EGM0097

EG-6 HOW TO USE THIS MANUAL Component Parts Location (Cont’d) COMPONENT SYMBOLS

EG-7 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS ECM Trouble Diagnosis CAUTION: • The following trouble diagnosis procedures are designed to identify the trouble causes efficiently. When performing diagnoses, carefully observe the following instructions. • Before starting a trouble diagnosis, carefully read and understand the contents in “Basic Inspection”, “Diagnosis Chart by Symptom” and “Trouble Diagnosis Flowchart”. • After the repair work, always verify that the trouble is eliminated. • For the locations of the parts and harness connectors, refer to “Component Parts Location” in the relevant section. • To perform a simple inspection, utilize the circuit diagrams. To inspect the circuit for continuity in details including the sub-harnesses, identify the relevant connectors and harness layouts referring to the “Wiring Diagrams”. • Before inspecting a circuit for continuity, always turn the ignition switch to OFF. • Before measuring voltage at a connector, always measure the battery voltage. • After finishing diagnoses or inspections, always ensure that all removed harness connectors are reconnected correctly.

TB45 Gasoline Engine With GP40N NF-FP5 service repair manual

You're Reading a Preview

Recently Viewed